US20240002084A1 - Improvements in and relating to packaging - Google Patents

Improvements in and relating to packaging Download PDF

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Publication number
US20240002084A1
US20240002084A1 US18/255,456 US202118255456A US2024002084A1 US 20240002084 A1 US20240002084 A1 US 20240002084A1 US 202118255456 A US202118255456 A US 202118255456A US 2024002084 A1 US2024002084 A1 US 2024002084A1
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United States
Prior art keywords
produce
items
item
end effector
stack height
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US18/255,456
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English (en)
Inventor
Andrew Vernon Fowler
Ryan Douglas Tasma
Shane Timothy Daly
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Rockit Global Ltd
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Rockit Global Ltd
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Assigned to Rockit Global Limited reassignment Rockit Global Limited ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FOWLER, Andrew Vernon, DALY, SHANE TIMOTHY, TASMA, Ryan Douglas
Publication of US20240002084A1 publication Critical patent/US20240002084A1/en
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B5/00—Packaging individual articles in containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, jars
    • B65B5/10—Filling containers or receptacles progressively or in stages by introducing successive articles, or layers of articles
    • B65B5/105—Filling containers or receptacles progressively or in stages by introducing successive articles, or layers of articles by grippers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00—Manipulators not otherwise provided for
    • B25J11/0045—Manipulators used in the food industry
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J15/00—Gripping heads and other end effectors
    • B25J15/0019—End effectors other than grippers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J15/00—Gripping heads and other end effectors
    • B25J15/02—Gripping heads and other end effectors servo-actuated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/0093—Programme-controlled manipulators co-operating with conveyor means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1628—Programme controls characterised by the control loop
    • B25J9/1653—Programme controls characterised by the control loop parameters identification, estimation, stiffness, accuracy, error analysis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
    • B25J9/1669—Programme controls characterised by programming, planning systems for manipulators characterised by special application, e.g. multi-arm co-operation, assembly, grasping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1679—Programme controls characterised by the tasks executed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B25/00—Packaging other articles presenting special problems
    • B65B25/02—Packaging agricultural or horticultural products
    • B65B25/04—Packaging fruit or vegetables
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B35/00—Supplying, feeding, arranging or orientating articles to be packaged
    • B65B35/06—Separating single articles from loose masses of articles
    • B65B35/08—Separating single articles from loose masses of articles using pocketed conveyors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B35/00—Supplying, feeding, arranging or orientating articles to be packaged
    • B65B35/10—Feeding, e.g. conveying, single articles
    • B65B35/16—Feeding, e.g. conveying, single articles by grippers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B35/00—Supplying, feeding, arranging or orientating articles to be packaged
    • B65B35/30—Arranging and feeding articles in groups
    • B65B35/44—Arranging and feeding articles in groups by endless belts or chains
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B35/00—Supplying, feeding, arranging or orientating articles to be packaged
    • B65B35/56—Orientating, i.e. changing the attitude of, articles, e.g. of non-uniform cross-section
    • B65B35/58—Turning articles by positively-acting means, e.g. to present labelled portions in uppermost position
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B43/00—Forming, feeding, opening or setting-up containers or receptacles in association with packaging
    • B65B43/42—Feeding or positioning bags, boxes, or cartons in the distended, opened, or set-up state; Feeding preformed rigid containers, e.g. tins, capsules, glass tubes, glasses, to the packaging position; Locating containers or receptacles at the filling position; Supporting containers or receptacles during the filling operation
    • B65B43/46—Feeding or positioning bags, boxes, or cartons in the distended, opened, or set-up state; Feeding preformed rigid containers, e.g. tins, capsules, glass tubes, glasses, to the packaging position; Locating containers or receptacles at the filling position; Supporting containers or receptacles during the filling operation using grippers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B43/00—Forming, feeding, opening or setting-up containers or receptacles in association with packaging
    • B65B43/42—Feeding or positioning bags, boxes, or cartons in the distended, opened, or set-up state; Feeding preformed rigid containers, e.g. tins, capsules, glass tubes, glasses, to the packaging position; Locating containers or receptacles at the filling position; Supporting containers or receptacles during the filling operation
    • B65B43/54—Means for supporting containers or receptacles during the filling operation
    • B65B43/56—Means for supporting containers or receptacles during the filling operation movable stepwise to position container or receptacle for the reception of successive increments of contents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B57/00—Automatic control, checking, warning, or safety devices
    • B65B57/10—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged
    • B65B57/14—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged and operating to control, or stop, the feed of articles or material to be packaged
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
    • B65G47/74—Feeding, transfer, or discharging devices of particular kinds or types
    • B65G47/90—Devices for picking-up and depositing articles or materials
    • B65G47/91—Devices for picking-up and depositing articles or materials incorporating pneumatic, e.g. suction, grippers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
    • B65D85/30—Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure
    • B65D85/34—Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure for fruit, e.g. apples, oranges or tomatoes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G2201/00—Indexing codes relating to handling devices, e.g. conveyors, characterised by the type of product or load being conveyed or handled
    • B65G2201/02—Articles
    • B65G2201/0202—Agricultural and processed food products
    • B65G2201/0211—Fruits and vegetables
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
    • B65G43/08—Control devices operated by article or material being fed, conveyed or discharged
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
    • B65G47/22—Devices influencing the relative position or the attitude of articles during transit by conveyors
    • B65G47/24—Devices influencing the relative position or the attitude of articles during transit by conveyors orientating the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
    • B65G47/22—Devices influencing the relative position or the attitude of articles during transit by conveyors
    • B65G47/26—Devices influencing the relative position or the attitude of articles during transit by conveyors arranging the articles, e.g. varying spacing between individual articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
    • B65G47/74—Feeding, transfer, or discharging devices of particular kinds or types
    • B65G47/90—Devices for picking-up and depositing articles or materials
    • B65G47/902—Devices for picking-up and depositing articles or materials provided with drive systems incorporating rotary and rectilinear movements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G57/00—Stacking of articles
    • B65G57/02—Stacking of articles by adding to the top of the stack
    • B65G57/03—Stacking of articles by adding to the top of the stack from above
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G61/00—Use of pick-up or transfer devices or of manipulators for stacking or de-stacking articles not otherwise provided for
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/45—Nc applications
    • G05B2219/45048—Packaging

Definitions

  • the invention relates to an apparatus for packaging objects in a tube, and in particular, for packing items of produce such as fruit or other perishable/food items in a tube.
  • Apples and other items of fruit are traditionally packaged in boxes. To minimize damage to fruit, typically fruit is supported in a tray within a box to keep fruit separated from adjacent fruit.
  • a single box may include one or more layers of fruit, with each layer supported by a tray.
  • the applicant introduced a novel approach to packaging fruit (apples), by packing apples in a tube rather than in trays in a box
  • Each tube typically contains two or more items of fruit, for example five apples.
  • the tube may be cylindrical in shape or may have over shapes in cross section, for example square, triangular or other shape
  • An inner dimension of the tube is commensurate with an outer dimension of the fruit so that when full, the tube contains a single row or column of fruit.
  • an inner diameter of the tube is preferably slightly larger than a maximum expected diameter of the fruit.
  • the expected maximum diameter of fruit may be based on a known distribution of fruit size for a particular variety and/or type of fruit.
  • Packing fruit in a tube can introduce inefficiencies in the packing process. Each item of fruit cannot be dropped into the tube, since physical impacts between fruit, can cause damage to the fruit during packing (bruising).
  • each item of fruit must be separately added to the tube one at a time. Accordingly, this form of packaging/packing process is time consuming, labour intensive and adds further costs to the packing process.
  • a further issue with the packing of fruit in a tube is that natural variability in fruit size can result in variances the amount of empty headspace at the top of the tube. Ideally the amount of empty headspace within the tube should be kept to a minimum, to avoid fruit rolling around or moving too much within the tube.
  • fruit packaged in a tube that is too long can during transportation, result in the fruit moving significantly within the tube, and impacting adjacent fruit resulting in damage.
  • the headspace at the top end of the tube may be too large—such that the tube looks empty, and there is too much room for fruit movement within the tube and consequential damage thereto.
  • a desired number of items of fruit may be too large to fit within a tube requiring the packing process to be restarted once the tube is emptied.
  • a tube with a variable length may be provided, for example a tube that has two opposing portions that telescope/slide together to vary a tube length.
  • a tube comprising multiple parts may add further cost and/or complexity to the packaging of fruit.
  • a produce packing device comprising:
  • the acceptable stack height is defined by a target stack height and/or an acceptable stack height range, wherein the acceptable stack height range is from a minimum acceptable stack height to a maximum acceptable stack height.
  • each item of produce assumes a position within the package, and a said acceptable stack height range and/or target stack height is defined for the items of produce at each position within the package.
  • the controller is configured to:
  • the device comprises a conveyor to convey the plurality of items of produce to the robot positioning device and the present subset of items of produce is a row of items of produce spaced apart across the conveyor.
  • the controller is configured to track the row of items of produce as the row is conveyed along the conveyor.
  • the controller is configured to determine the size of each item of produce in more than one row of items of produce, and track the rows of items of produce as the rows are conveyed along the conveyor.
  • the controller is configured to:
  • step (iii)(c) the controller is configured to:
  • step (iii)(c) the controller is configured to:
  • step (ii) if there is more than one selection of one or more items of produce from the present subset to achieve a stack height within an acceptable stack height range, the controller is configured to:
  • a stack height of a selection of one or more items of produce is equal to the target stack height if the stack height of the selection is equal to the target stack height plus or minus a threshold.
  • the controller is further configured to:
  • the end effector is adapted in use for holding the package and places the item of produce therein as a consequence of the end effector picking up said item of produce, and wherein, in step (v):
  • the controller is configured to:
  • the end effector is adapted in use for holding the package and places the item of produce therein as a consequence of the end effector picking up said item of produce, and the end effector comprises:
  • the controller is further programmed to:
  • the device comprises a conveyor to convey the plurality of items of produce to the robot positioning device with end effector, and the subset of items of produce is a row of items of produce spaced apart across the conveyor, and wherein, to position the end effector vertically above an item of produce, the controller is configured to:
  • the end effector is adapted in use for holding the package and places the item of produce therein as a consequence of the end effector picking up said item of produce.
  • the device comprises a singulation unit to space apart the items of produce and present singulated items of produce to a reach envelope of the robot positioning apparatus.
  • the singulation unit spaces the items of produce apart in a 2-dimensional array.
  • a method of packaging items of produce directly into a tube-like container comprising the steps of:
  • the method comprises the further step of:
  • the method comprises the further step of:
  • a method of packaging items comprising the step of :
  • the method comprises the further step of:
  • a method of packaging items comprises the step of:
  • the method comprises the further step of wherein the assessment of the collective dimensions, collective dimensions and shape, or collective dimensions, shape, and orientation are used to determine the order in which items of produce are packed into a tube.
  • a sensor system for a tube packaging operation which is configured to:
  • the sensor system for a tube packaging operation is also configured to:
  • robot is to be understood as meaning manipulators or industrial robots which have one or more joints, which in particular can perform translatory and/or rotational movements, such that one or more end-effectors of a robot have different positions (spatial positions or positions).
  • Translational and/or rotational movements may include, movements along one or more rails on which parts/arms (links) of the robot are guided. Even such rails thus form joints in the sense of a kinematic chain, which describes the possibility of movement of a robot.
  • robot as used herein may be understood to mean an apparatus comprising a Cartesian robot/gantry robot, SCARA robot/horizontal articulated robot, cylindrical robot/cylinder coordinate robot, spherical robot/spherical coordinate robot, articulated robot.
  • robot or ‘robot positioning apparatus’ as used herein may be understood to mean an apparatus configured to move with at least three degrees of freedom, including three translational degrees of freedom, or an apparatus configured to move with at least three translational degrees of freedom and at least one rotational degree of freedom.
  • resilient refers to the ability of a material to return to its original shape after being deformed due to an applied force.
  • tube refers to any elongate container which has a base one or more side walls and an open top and a hollow interior.
  • tube and tube-like' can be used interchangeably and cover elongate containers with different cross-sections including circular, rectangular, triangular, pentagonal, hexagonal to name a few possible cross-sectional profiles.
  • FIG. 1 illustrates a produce packing device for placing items of produce in tubular packages.
  • the illustrated packing line is particularly adapted for packing apples;
  • FIG. 2 illustrates a singulation unit of the produce packing device of FIG. 1 , for singulating or separating items of produce into a 2-D array;
  • FIG. 3 illustrates a portion of the produce packing device of FIG. 1 , including a robot positioning apparatus with end effector for picking items of produce for packing in a tubular package;
  • FIG. 4 illustrates a portion of the produce packing device of FIG. 1 , including a robot positioning apparatus with end effector and with a tracking area of the robot positioning apparatus identified;
  • FIG. 5 illustrates an end effector configured to hold a tubular container in an inverted orientation and pick up items of produce to fill the tubular container held by the end effector;
  • FIG. 6 is a cross sectional view of the end effector of FIG. 5 holding a tubular package that has been filled with apples;
  • FIG. 7 is a cross sectional view of a tubular package containing five apples
  • FIGS. 8 to 10 are flow charts illustrating a packing operation performed by the produce packing device of FIGS. 1 to 4 .
  • FIG. 11 shows an effector which includes a vibrating mechanism thereon in accordance with preferred embodiment of the present invention.
  • FIG. 12 shows a perspective view of a preferred actuatable element used on the end effector shown in FIGS. 5 to 7 .
  • FIGS. 1 to 4 illustrate a produce packing device or system 100 for packing items of produce such as fruit in tubular packages.
  • the fruit is apples.
  • the producing packing device or system (herein the packing device) 100 comprises at least one robot positioning apparatus 3 with an end effector 1 (refer FIGS. 3 and 4 ) for placing the items of produce in a tubular package.
  • the illustrated embodiment has three robot positioning apparatuses 3 each carrying an end effector 1 . However, there may be one, two, three or more robot positioning apparatuses 3 with end effectors 1 .
  • the illustrated device 100 comprises a singulation unit 101 configured to singulate (separate) the items of produce to be presented to the robot positioning apparatus 3 with end effector 1 .
  • the singulation unit 101 separates the items of produce to space the produce apart in at least a line or row.
  • the singulation unit 101 separates the produce via line dividers 103 into six channels C to space the produce apart in two dimensions—i.e. spaced apart in a two-dimensional array.
  • the produce encounters a wall section, which stops forward motion of the leading produce in channel on a lift section which has a top surface on which fruit sit inclined downwardly in the downstream direction.
  • the lift section spans across the base of channels C and is operated to raise the lead produce adjacent the wall to deliver via the sloped top surface thereof to a downward ramp section Cl which has a gate G at the end thereof. This lifting operation is timed to occur, just after the gate G has opened, to release items of produce into the holders 108 .
  • the ramp is made of Teflon a high friction surface so as to help slow the descent of the produce.
  • the release of produce from the downstream end of the channels C is controlled by the gate G—which is opened and closed by an actuator A—so that items of produce in channels C can be released at timed intervals into holders 108 . This is further described below.
  • the items of produce are then spaced apart in x and y directions.
  • the singulation unit 101 comprises a conveyor 109 to transport the singulated items of produce to the reach envelope of the or each robot positioning apparatus 3 .
  • the conveyor 109 may be described as a singulated conveyor 109 since the conveyor 109 supports each item of produce to be sufficiently spaced apart from adjacent items of produce to allow the robot positioning apparatus 3 and end effector 1 to pick up an individual item of produce without contacting adjacent items of produce.
  • the singulated conveyor 109 comprises a continuous conveyor loop or belt 110 carrying a plurality of holders 108 .
  • the holders 108 are spaced apart in a conveying direction (y direction) along the conveyor belt 110 .
  • the singulated conveyor comprises holders 108 spaced apart in the conveying direction along the conveyor belt 110 and orthogonal to the conveying direction across the conveyor belt (x direction) to be spaced apart in two dimensions to present the items of produce to the robot positioning apparatus and end effector in a 2-dimensional array.
  • Each holder 108 holds a single individual item of produce and represents a position on the conveyor (or in the 2-dimensional array).
  • the singulation unit 101 comprises an infeed conveyor 102 and a plurality of line dividers 103 .
  • the infeed conveyor may comprise one or more conveying apparatuses such as a conveyor belt to move the produce in a conveying direction.
  • the infeed conveyor 102 conveys the produce towards the line dividers 103 ( FIG. 2 ) to separate the produce into at least one column or lane of produce, and preferably a plurality of adjacent columns of produce to correspond to the number of holders 108 spaced apart across the singulated conveyor 109 .
  • the produce continues to be conveyed on the infeed conveyor 102 along columns defined by the line dividers 103 towards a separating device 104 .
  • the separating device is configured to space the items of produce apart in a longitudinal or conveying direction (so that each item of produce is received onto a holder 108 of the singulated conveyor.
  • An example singulation unit 101 comprising an infeed conveyor 102 , line dividers 103 , separating device 104 and singulated conveyor 109 with holders 108 is described in co-pending patent application NZ763219, the entire contents of which is incorporated herein by reference.
  • the robot positioning apparatus 3 may comprise an articulated robotic arm or other apparatus capable of moving the end effector in a 3-dimensional space.
  • the robot positioning apparatus 3 provides at least three degrees of freedom of movement, so that the robot positioning apparatus is adapted to move the end effector in x, y and z translational directions to position the end effector in a 3-dimensional space.
  • the robot positioning apparatus 3 provides at least four degrees of freedom of movement, so that the robot positioning apparatus is adapted to move the end effector in x, y and z translational directions, and including at least one rotational direction (e.g. roll) to allow the end effector to rotated about a horizontal axis to be inverted.
  • rotation about a horizontal axis may invert the tube so that the tube has an upside-down orientation (with the open lop end' of the tube facing substantially downwardly) or re-orienting the tube so the open lop end' now faces substantially vertically upwards.
  • the x direction may be a horizontal direction (e.g. across the conveyor), the y direction may be a horizontal direction orthogonal to the x direction (e.g. a conveying direction of the conveyor), and the z direction vertical.
  • the end effector 1 is adapted to hold an open topped tubular container 2 in an inverted orientation with an open top of the container presented downwards.
  • the end effector 1 has two actuatable movable elements 7 adjacent the open end of a tube 2 held by the end effector 1 .
  • the actuatable movable elements 7 are configured to be operable between an extended position which at least partially extends over the open end of a tube 2 held by the end effector 1 to at least partially obstruct the open end of the tube, and a retracted position so that the open end 2 of the container is substantially unobstructed to allow items of produce to be received in the tube.
  • the end effector preferably also comprises a holding arrangement 10 configured to grip the tubular container, to hold the tubular container within the end effector 1 .
  • end effectors arrangements may be utilised, for example to pick up and place produce in a tube that is not carried by the end effector.
  • FIG. 12 shows an actuatable moveable element 7 which has an apple stop portion 7 a which holds apples in the tube when the actuatable moveable element is in the extended position.
  • the actuatable moveable element 7 has an aperture 7 b which is used to connect the actuatable moveable element 7 to an actuator (not shown).
  • an actuator not shown.
  • the actuatable moveable element 7 may be made from blue urethane or similar material.
  • a tubular container 2 (refer FIGS. 5 - 7 ) is received in a frame 5 —of the end effector 1 —which is substantially cylindrical in shape.
  • the robot positioning apparatus 3 may move the end effector 1 to a tube dispenser 120 (as shown in FIG. 4 ) to receive a tube 2 in frame 5 from the upper end or the lower end of the tube dispenser 120 .
  • a person may insert or place a tubular container into the frame 5 of the end effector 1 .
  • a controller for example a PLC is provided to control movement of the robot positioning apparatus 3 and actuation of the end effector 1 .
  • the controller may be internal to, or external to (i.e., remotely located from), the robot positioning apparatus.
  • the robot positioning apparatus is controlled to first move the end effector 1 —carrying a tubular container 2 in an inverted position—to be vertically above a selected item of produce located on a holder 108 on the conveyor 102 .
  • the robot positioning device may be moved in three axial directions (x, y, and z) or a combination of at least two of these axial directions in the nature of a vector direction.
  • the robot positioning apparatus is then controlled so the end effector 1 remains positioned vertically above the item of produce on the conveyor and thus keeps the end effector 1 moving in a conveying direction (direction y) at the same speed as the conveyor.
  • the robot positioning apparatus 3 moves the end effector 1 vertically downwards over the item of produce, with the opposed pair of actuatable moveable elements 7 both in the retracted position to receive the item of produce in the tubular package 2 retained by the end effector 1 .
  • the actuatable moveable elements 7 are both driven by actuators 9 .
  • the actuatable element is actuated to move from the retracted position to the extended position to retain the item of produce in the container 2 , and the robot positioning apparatus 3 lifts the end effector and therefore item of produce from the holder 108 .
  • the robot positioning apparatus keeps moving in the conveying direction at the speed of the conveyor 109 and then moves laterally (i.e. in the x direction).
  • the robot positioning apparatus 3 can be subsequently controlled to move and accelerate as necessary to position the end effector 1 over a next, or further, item of produce to be packaged, and the vertical movement (i.e. the z direction) downwards and then upwards while simultaneously moving in the conveying direction, once aligned with the next item that has been selected for packaging, is repeated to pick up that item of produce.
  • the robot positioning apparatus moves the end effector 1 vertically downwards so that a first or previous item of produce already received in tube is adjacent to or in contact with the further item of produce.
  • the actuatable moveable element 7 is actuated to move to the retracted position, and the end effector moves down to receive the further item of produce in the tube.
  • the actuatable element is actuated to move from the retracted position to the extended position to retain the first or previous item of produce and the further item of produce in the tube.
  • the robot positioning apparatus 3 lifts the end effector and therefore items of produce while still moving in the conveying direction at the speed of the conveyor 109 .
  • Each next item of produce displaces the previous item of produce further into the container 2 , as the end effector 1 and therefore package 2 is moved vertically downwards over the next item of produce.
  • the robot positioning apparatus 3 with end effector 1 continues to pick up further items of produce until the tubular container is full.
  • the robot positioning apparatus 3 with end effector continues to pick up items of produce with the end effector until a predetermined number of items of produce have been received in the tubular container 2 .
  • the robot positioning apparatus may rotate the end effector 1 between the inverted orientation and an upright orientation.
  • the robot positioning apparatus 3 moves the end effector 1 to a release area 121 (refer FIGS. 3 and 4 ) to release the tubular container 2 from the end effector 1 .
  • the robot positioning apparatus 3 then lifts the end effector 1 off the tubular container 2 .
  • the release area 121 is actuated to move the full package onto an exit conveyor 122 to transport the full package from the packing device 100 .
  • FIG. 7 illustrates a full tubular container or package containing five apples.
  • the tubular package has a closed end and an open end.
  • a cap or lid (not shown) may be fitted to the open end of the tubular package to close the package and complete the packing operation.
  • items of produce may not be packaged before reaching an end of the singulation conveyor 109 . Any items of produce reaching an end of the conveyor may be collected and returned to the infeed conveyor 102 to be singulated again for packing. Items of produce may be collected in a container and returned to the infeed conveyor, for example by a person.
  • the produce packing device 100 comprises a sensor arrangement 111 to sense or detect each item of produce in the singulated items of produce on the singulated conveyor.
  • the device 100 comprises a controller with a memory in communication with the sensor arrangement 111 .
  • the controller is configured to store in the memory a datapoint of the position of each item of produce associated with a respective holder 108 holding the item of produce.
  • the singulation unit 101 presents items of produce in a 2-dimensional array and the controller stores in the memory a datapoint for each position in the 2-dimensional array.
  • Each position may be represented by an x, y coordinate.
  • the controller tracks the position of each item of produce as the conveyor moves the singulated produce in a conveying direction.
  • the robot positioning device 3 moves the end effector 1 to a holder to collect the item of produce based on the datapoint for the item of produce associated with the holder.
  • the sensor arrangement 111 comprises a sensor to detect a dimension for each item of produce.
  • the senor may comprise a distance measurement sensor 112 (refer FIG. 3 ) to determine a distance between the sensor 112 and each item of produce from which a height measurement for each item of produce can be determined.
  • a distance measurement sensor 112 (refer FIG. 3 ) to determine a distance between the sensor 112 and each item of produce from which a height measurement for each item of produce can be determined.
  • the senor 112 detects the height of each item of produce in a row of items of produce on the conveyor one row at a time.
  • An example sensor is a time of flight sensor, for example sensor model no. O3D302 provided by IFMTM.
  • the height for each item of produce is communicated to the controller.
  • the controller tracks the position of the row on the conveyor as the row is conveyed in a conveyor direction of the packing device.
  • the controller is configured to track the position of each item of produce in the row.
  • the controller determines which item of produce in each row to be picked up by the robot positioning apparatus 3 and end effector 1 to ensure a tubular package contains a correct number of items of produce in a single container and achieve a desired stack height of produce in the container.
  • the controller selects each item of produce to ensure that an amount of empty headspace within the tubular container will be within a desired or acceptable range, once the tubular container has the desired number of items of produce therein.
  • This selection process helps ensure the items of produce within the container will not roll around or move excessively within the container, during transit, to avoid damage to:
  • dimension measured by the sensor may be height or width.
  • width can be used in the assessment of stack height.
  • FIGS. 8 to 10 A preferred method or sequence of steps that the packing device implements for determining which item of produce to pick to achieve a desired stack height of produce within a single container is now described with reference to FIGS. 8 to 10 .
  • Stacking apples in a tube is provided by way of example, however, the method or sequence of steps may be used to package other types of produce
  • the method involves packing items of produce according to a desired or acceptable stack height.
  • the desired or acceptable stack height is defined by an acceptable minimum stack height, a target stack height and an acceptable maximum stack height.
  • a minimum, target and maximum stack height is defined for each item of produce as the tube is filled, i.e. once packaged each item of produce assumes or is located at a position within the tube, and there is a minimum, target and maximum stack height for each position in the tube.
  • the following example minimum, target and maximum stack heights are provided which take into an acceptable headspace for the tube once filled with apples:
  • the tubular package may have a length of around 260 mm, such that the headspace at the end of the tube is a maximum of 20 mm in length.
  • the controller receives one or more outputs from the sensor 112 indicative of the size (i.e. the height) of each apple in a row.
  • the controller determines from the one or more outputs from the sensor 112 a height measurement for each apple in a present row of apples on the conveyor.
  • the row is a sub-set of items of produce in a plurality of items of produce presented to the robot positioning apparatus.
  • the controller tracks the present row as the row is conveyed along the conveyor.
  • FIG. 4 illustrates a tracking window 113 in which the controller tracks one or more rows as the row(s) (or sub-sets of items of produce) move along the conveyor.
  • the controller evaluates the heights of the apples in the present row of apples, to determine if there is one or more choices of a selection of one or more apples in the row to achieve a stack height within the acceptable stack height range of the minimum to maximum stack height.
  • step 203 the controller assesses if there is a single selection of one or more apples to achieve an acceptable stack height range.
  • the controller causes the robot positioning apparatus and end effector to pick the one or more apples to achieve a stack height within the acceptable stack height range.
  • the controller evaluates the apples added to the tube to determine if the tube is full. If the tube is full, the packing operation is completed, and the controller causes the robot positioning apparatus to move the end effector to the release area 120 and release the full tube from the end effector.
  • the controller may cause the robot positioning apparatus with end effector to pick up a new empty tube and commence a new packing operation.
  • step 209 the controller ‘drops’ the present row, since the controller has completed its evaluation of the present row, and selects the next row on the conveyor to become the present row for evaluation, and the controller returns to the beginning of the method to repeat the method to continue to fill the tube within the desired stack limit range.
  • step 203 if there is no selection of apples that achieves a stack height within the acceptable range, then at step 205 , if the stack height is greater than the maximum stack height, the controller ‘removes’ or ‘drops’ (i.e. the controller disregards) the largest apple from the controller's evaluation of the present row of apples, or, if the stack height is less than the minimum stack height, the controller ‘removes’ or ‘drops’ (i.e. the controller disregards) the smallest apple from the controller's evaluation of the present row of apples.
  • the controller determines if there is more than one apple available for selection left in the row.
  • the controller returns to step 202 .
  • step 202 the controller again evaluates the apples remaining in the row for selection.
  • the acceptable stack height range is 190 mm to 210 mm.
  • the controller repeats steps 203 , 205 and 206 until a stack height of apples remaining in the row is within the acceptable range and the controller moves to step 204 , or there is only one apple left in the row for evaluation and the controller moves to step 207 .
  • the controller causes the robot positioning device and end effector to pick up the apple at step 204 .
  • step 208 if the tube is full the packing operation is completed, otherwise, at step 209 , the controller selects the next row on the conveyor to become the present row for evaluation, and the controller returns to the beginning of the method to repeat the method to continue to fill the tube within the acceptable stack limit range.
  • the controller determines from the one or more outputs from the sensor 112 a height measurement for each apple in the next three rows on the conveyor, and at step 302 , evaluates the heights of the apples in the next three rows to determine if there is an apple in the next three rows to bring the stack height back into the acceptable stack height range. If there is an apple in the next three rows to bring the stack hight back into range, at step 303 the controller causes the robot positioning apparatus and end effector to pick the last apple from the present row.
  • step 208 to step 209 the controller selects the next row on the conveyor to become the present row for evaluation, and the controller returns to the beginning of the method to repeat the method to continue to fill the tube within the acceptable stack limit range.
  • the controller evaluates the apple heights in the next three rows to try and locate an apple to bring the stack height back into range
  • the controller may evaluate the next row only, or the next two rows, or the next three rows, or more than the next three rows to try and locate an apple to bring the stack height back into range. Evaluating the next three rows is provided by way of example only.
  • step 202 if the controller determines there is more than one choice of a selection of one or more apples from the present row of apples to achieve the acceptable stack height, then, with reference to FIG. 10 , at step 401 the controller evaluates the present row of items of produce and determines which of the selections of one or more items of produce in the present row is the closest to, or is equal to, the target stack height.
  • the controller determines if there is more than one selection of one or more apples that is the closest to or is equal to the target stack height.
  • the controller may determine a stack height that is the closet to, or is equal to, the target stack height, or if the measured stack height is equal to the target stack height plus or minus a threshold.
  • the threshold may be product specific and/or adjustable, e.g. expressed as a percentage of the stack height limit. If there is only one selection of one or more apples that is the closest to or equal to the target, then at step 403 the controller causes the robot positioning apparatus with end effector to pick up the selection of items of produce that has a stack height that is the closest to, or equal to, the target stack height.
  • the controller causes the robot positioning device to pick up the selection of items of produce that includes the largest outlier, that is the largest or smallest item of produce of the selections of items of produce that have a stack height within the acceptable stack height range.
  • the controller may determine an ‘outlier score’ for each item of produce. The outlier score may be based on a difference between the actual size (height) of an item of produce and a nominal size (height).
  • the outlier score may be the difference between the actual size (height) of an item of produce and a nominal size (height) to the power of 2.
  • the nominal size item of produce is 50 mm.
  • the outlier score is 25.
  • the step of picking up the selection of items of produce with the largest outlier is useful where the produce packing device 100 includes more than one robot positioning device with end effector, as removing the largest outlier item of produce from the produce to be packed improves the likelihood of the next robot positioning device with end effector successfully filling a tube within the desired stack height range.
  • the controller determines if the tube is full.
  • the controller causes the robot positioning apparatus to move the end effector to the release area 120 and release the full tube from the end effector.
  • the controller may cause the robot positioning apparatus with end effector to pick up a new empty tube and commence a new packing operation.
  • the controller then sets the next row on the conveyor to become the present row for evaluation and repeats the method for filling the new tube.
  • step 209 the controller ‘drops’ the present row, since the controller has completed its evaluation of the present row, and selects the next row on the conveyor to become the present row for evaluation, and the controller returns to the beginning of the method to repeat the method to continue to fill the tube within the acceptable stack height range.
  • FIG. 11 is a cross-sectional view of a preferred ‘outlier’ end effector 1 A which can handle 90% of fruit to be packaged in a tube except for the remaining 10% of upper and lower outliers from the general population of fruit to be packaged.
  • This end effector 1 has a frame 5 which is attached to an outlier receiver section 1100 via a pair of collars 1101 a , 1101 b and a flexible joint 1102 .
  • the flexible joint may be made from thermoplastic or other suitable material.
  • the outlier receiver section 1100 has a vibration motor and housing 1103 which vibrates the outlier receiver section 1100 whilst it is receiving a new item of produce to be received and retained into the tube (not shown).
  • a further feature of this end effector 1 A is a hook 1104 which helps correctly position a tube into the end effector 1 A.
  • the inventors have found that in different growing seasons the uniformity of fruit size and/or shape for apples can vary—e.g. outlier apples can be long, squat, leaf or penguin shaped. These differences in size and shape from the average size/shape of an apple can cause difficulties with automated packaging of the apples directly into containers by the robot positioning device of the present invention.
  • shape, size (diameter) and/or cuticle adhesiveness can cause jamming issues with placing apples into the tube.
  • the inventors have been able to overcome 90% of these issues by utilising a vibrating mechanism on the end effector which operates during the tube filling process to vibrate the tube.
  • FIG. 11 shows an end effector 1 which includes a motor M which rotates an eccentric mass to vibrate the tube 2 .
  • the motor M is attached to the frame of the end effector 1 via collars C 1 and C 2 .
  • Assessing extreme outlier fruit which will not fit within the tube 2 is also achieved via a sensor system in the form of two Sick Inspector PIM60 smart 2D cameras (camera system) each simultaneously looking at three lanes L of the conveyor 109 upstream of the robot positioning apparatus 3 .
  • the camera system can measure apple diameter on four diagonals across three apple positions with a Standard Deviation of 0.27 mm from the actual diameter.
  • This camera system is able to detect the outlier fruit to a tolerance of +/ ⁇ 0.5 mm.
  • an elongation profile of each apple can be made.
  • the Auto-packing machine can then decide to reject it or add it to its tube pick combination.
  • the sensor system of the present invention thus can take multiple measurements of an item of produce over a period of time to make a determination that it can fit within a tube. If the fruit cannot the fruit is identified.
  • the sensor system can also assist with programming of the robotic positioning apparatus 3 so that it picks up the smallest fruit that will form a stack within a tube first with the largest fruit in the stack going into the tube last.
  • extreme outlier fruit may be picked up by additional downstream robotic positioning devices which have tubes of an appropriate oversized or undersized diameter tubes for receiving the extreme outlier produce.
  • the invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Robotics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Agronomy & Crop Science (AREA)
  • Food Science & Technology (AREA)
  • Container Filling Or Packaging Operations (AREA)
  • Packaging Of Special Articles (AREA)
  • Manipulator (AREA)
  • Packaging Frangible Articles (AREA)
  • Stacking Of Articles And Auxiliary Devices (AREA)
  • Specific Conveyance Elements (AREA)
US18/255,456 2020-12-01 2021-12-01 Improvements in and relating to packaging Pending US20240002084A1 (en)

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DE102006061571A1 (de) * 2006-12-27 2008-07-03 Robert Bosch Gmbh Verfahren und Vorrichtung zum Umsetzen von Stückgütern
ITMO20120266A1 (it) * 2012-10-31 2014-05-01 Charlotte Anna Maria Liedl Dispositivo per l'orientazione di oggetti.
NL2016363B1 (nl) * 2016-03-04 2017-09-19 De Greef's Wagen- Carrosserie- En Machb B V Verpakkingsinrichting en sorteersysteem voor het gericht verpakken van producten en werkwijze daarvoor.
CN109311545A (zh) * 2016-04-21 2019-02-05 机器人技术普卢斯有限公司 包装机器人
WO2019136530A1 (en) * 2018-01-15 2019-07-18 Auzfresh Holdings Pty Ltd Apparatus for manufacturing a container
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